What is Cycle Time? | Definition, Measurement & Optimization
Cycle time is the total elapsed time from the start to the end of a process or operation needed to produce one unit. In manufacturing, it includes all manual work, machine processing, and any waiting or transition time within a single work cycle. Accurate cycle time measurement is the foundation of line balancing, capacity planning, and continuous improvement.
How to Create
To measure cycle time accurately: (1) Define the start and end points of the work cycle clearly. (2) Observe and record multiple consecutive cycles (at least 10-20 for statistical reliability). (3) Separate the cycle into individual work elements: manual work, machine time, walk time, and wait time. (4) Record the time for each element. (5) Calculate the average, minimum, and maximum cycle times. (6) Identify variation sources and non-value-added time. Video-based tools like Yamazo Studio enable frame-accurate cycle time measurement by tagging work elements directly on recorded video.
Example
An operator at an assembly station performs: pick up components (3s), place on fixture (4s), tighten 4 screws (16s), inspect (5s), place finished part on conveyor (2s). The total cycle time is 30 seconds. However, measuring 20 consecutive cycles reveals variation from 27 to 35 seconds. The average is 30.5 seconds, but the variation suggests inconsistency in the screw-tightening step that should be investigated.
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